US8962151B2 - Method of bonding solid materials - Google Patents
Method of bonding solid materials Download PDFInfo
- Publication number
- US8962151B2 US8962151B2 US11/891,429 US89142907A US8962151B2 US 8962151 B2 US8962151 B2 US 8962151B2 US 89142907 A US89142907 A US 89142907A US 8962151 B2 US8962151 B2 US 8962151B2
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- mca
- laser
- bonding
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- formation
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Definitions
- This disclosure pertains to a method of bonding solid materials. More particularly, it relates to bonding different materials with a method that includes formation of a micro-column array (MCA) on at least one surface.
- MCA micro-column array
- MCA Micro-Column Arrays
- Bonding processes are essential for large-scale manufacturing of components that employ titanium and aluminum base alloys, steels, ceramics, and composite structures.
- bonding processes for similar metals include welding, brazing, and solid-state diffusion bonding. Bonding of dissimilar materials is much more complicated, especially at elevated temperatures, because compensation for the difference in the coefficients of thermal expansion (CTE) is required. Also, changes in chemical and structural properties that may occur during the thermally induced stress must be considered.
- W ad is defined as the bond energy needed (per unit area) to reversibly separate an interface into two free surfaces, neglecting plastic and diffusional degrees of freedom.
- ⁇ iv is the surface energy of slab i
- ⁇ 12 is the total interface energy
- E i tot is the total surface energy of slab i
- E 12 tot to is the total energy of the interface system.
- a s represents the total specific interface area.
- Micro-Column Arrays can improve bonding between any solid materials performed by using adhesive or specialty brazing by not only increasing the area of the interface and reducing the stress due to the synergetic effect of the micro-deformations of single micro-cones, but also by promoting better wetting of the layer surface by the adhesive or the braze material due to the highly developed surface morphology.
- MCA Micro-Column Arrays
- Bonding refers to any process by which two materials are attached to one another by using a third material between them referred to as “bonding material”—e.g., melting brazing material or placing an adhesive between the materials to be bonded.
- brazing and “joining” are synonymous and may be used interchangeably.
- Bonding material refers to anything placed between the two materials to be bonded that becomes part of the final bond. It includes, but is not limited to, various adhesives (e.g., epoxies), brazing, sintering materials, and solder. In the case of braze, for some applications it may be desirable to place a prebraze on a surface prior to applying the braze. Thus, prebraze is also a “bonding material” as the term is used in this disclosure.
- Brazing is widely accepted as a viable method for joining metals and ceramics. Brazing technology is particularly important in applications where metal ceramic composites cannot be used. These applications involve joining of highly dissimilar materials and the resulting joint has to sustain very high thermal and mechanical stresses.
- One example of conventional active metal brazing between titanium and fluorosilicate machinable ceramic-glass is given by using a 64 Ag-34.5 Cu-1.5 Ti (wt. %) brazing alloy. The reaction between the braze alloy and both materials at a temperature of 830° C. in vacuum leads to formation of multilayered interfaces with an average shear strength of more than 85% of the glass-ceramic bulk strength.
- a metal-ceramic composite substitute has been produced by joining a metal plate to a ceramic substrate by using a brazing material in a paste form comprising Ag—Cu-Active Metal-TiO powder.
- 97(Ag28Cu)3Ti and 97(Ag40Cu)3Ti (wt. %) braze alloys exhibited good performance for brazing of Al 2 O 3 in vacuum at temperatures up to 1200° C.
- Brazing alloys for joining metal and ceramic plates can also contain 70-75 wt. % Ni, 45-55% wt. % Co, and 0.5-5 wt. % Ti.
- a very important application area of high-temperature bonding of dissimilar materials is in the aerospace and military industries, where bond resistance to high and rapid thermal and mechanical loads is required.
- ceramic radomes used in various aerospace vehicles exhibit low weight, high temperature strength, electromagnetic transmissibility, and thermal insulation at boundary layer temperatures over 425° C.
- the problems associated with the bond durability stem from fundamental differences in the CTE and thermal conductivity.
- the ceramic has a relatively low CTE, and the metal missile body has a relatively high CTE.
- the thermal conductivities are very different too, which actually adds to the problem.
- the radome mounting bracket of the metal airframe may become hotter than the ceramic radome because of the differing thermal conductivity characteristics.
- a method for bonding two objects comprising forming a micro-column array on a surface of at least one of the objects, applying a bonding material to at least one surface of the objects, and bonding the objects is disclosed.
- FIG. 1 shows a cross section of two materials bonded in a preferred embodiment of the disclosed method.
- FIG. 2 is a SEM photograph of a MCA formed on titanium.
- FIG. 3 illustrates a method for improving MCA fabrication by preheating the surface with an unfocused laser beam.
- FIG. 4 is an illustration of a laser focusing method.
- FIG. 5 is a microscope photograph of the surface structure of a MCA surface showing oxidized spherical particles.
- the marker corresponds to 2 ⁇ m.
- FIG. 6 is a titanium-coated MCA fabricated on an iron substrate by pulsed laser ablation in a mixture of methanol and titanium chloride.
- FIG. 7 is a drawing illustrating micro-deformation of cones under shear stress in the presence of an adhesive or braze.
- FIG. 8 is a photograph of a fractured surface showing brittle fracture of epoxy.
- FIG. 9 is load-elongation plots for adhesive-bonded titanium samples with and without MCA.
- FIG. 10 shows a single lap configuration of a titanium alloy coupon brazed to a Intrinsically Reinforced Barium Alumo-Silicate (IRBAS) ceramic coupon using a conventional furnace.
- IGBT Intrinsically Reinforced Barium Alumo-Silicate
- FIG. 11 shows stress-elongation plots for plain titanium alloy samples brazed in a conventional furnace to ceramic samples both with MCA and without MCA (plain).
- FIG. 12 shows stress-elongation plots for titanium alloy and IRBAS samples both without MCA (plain) and with MCA brazed together in a conventional furnace.
- the present disclosure relates to the use of one or more Micro-Column Arrays (MCA) to improve bonding between surfaces, which may be the same, similar, or even very dissimilar materials. Because of the inherent difficulty in bonding dissimilar materials, this disclosure and the examples herein will focus on such applications. However, it will be apparent that the disclosed methods may be utilized for bonding a wide variety of materials. Therefore, the disclosed methods are applicable to bonding in general and not solely to bonding dissimilar materials.
- MCA Micro-Column Arrays
- a MCA is formed on one or both surfaces to be bonded. This may be performed by any method for creating MCA or an equivalent structure, with laser treatments being preferred. Any process for bonding materials may be used to bond the materials after the MCA is formed. The preferred method is brazing, but other methods, including but not limited to using solder or adhesive, may be used instead. In most embodiments, a bonding material is placed on one or both surfaces. Depending on the application and the materials used, the bonding material may be placed on the substrate surface before or after MCA formation. The surfaces, one or both of which may now be coated with bonding material, are then brought into contact with one another, with the bonding material in between.
- the bonding material may be heated (in case of braze or solder), cured (in case of adhesive), or otherwise activated. Depending on the materials and bonding material, some amount of pressure may be necessary to keep the bonded parts in contact and to improve wetting of the material surfaces by the bonding material.
- FIG. 1 illustrates a preferred embodiment, where MCA 60 formed on the surface of the first material 61 and the second material 62 .
- the bonding material 64 is placed in between two MCA-structured surfaces. The “sandwich” structure is then processed to form a bond.
- MCA are preferably formed by laser treating a surface, but can be formed by different methods including electron and ion beam processing (Lun Dai, Bei Zhang, Ruo Peng Wang, Jing-Yu Lin and Hong-Xing Jiang Optical resonant modes in InGaN MQW/GaN micro-cone. Current Applied Physics Volume 2, Issue 5, October 2002, Pages 383-387; Berglund et al. U.S. Pat. No. 6,145,438, 2000), photolithography and etching (I. K. Kwon and T.
- MCA are produced by pulsed laser ablation of the substrate material combined with mechanical translation of sample material to create cone-shaped micro tips interspersed with cone-shaped micro cavities.
- the formation of cone-shaped micro-columns in an array protruding above the surface is the result of redistribution of surface material melted by the laser ablation process.
- One important parameter in MCA formation through laser ablation is the laser fluence, which should heat the surface material to near or just slightly above melting point.
- a second important parameter is the number of laser pulses applied to any particular surface location.
- MCA may be generated on many material surfaces, including the following: Fe, Si, Ge, Ag, Au, W, Mo, Ta, Nb, V 2 O 5 , Ni, steel alloys (including stainless steel alloys), Ti alloys, as well as AlN (Aluminum Nitride), SiC (Silicon Carbide), BAS (Barium Aluminum Silicate), and IRBAS (Intrinsically Reinforced Barium Alumo-Silicate) ceramics.
- FIG. 2 is a Scanning Electron Microscope (SEM) photograph of an MCA on titanium (Ti).
- the surface of Ti is covered by a dense array of micro-cones with average spacing of 15-20 m. Formation of this kind of structure occurs under a large number of laser shots each having a fluence close to the threshold of the target material melting point. The structures emerge due to re-distribution of the ablated and/or melted target material.
- Bonding techniques for similar metals include welding, brazing, and solid-state diffusion bonding, including high temperature applications. Bonding of dissimilar materials is much more complicated, especially at elevated temperatures, because it is necessary to compensate for the difference between the coefficients of thermal expansion (CTE) for each material—i.e., the bonded materials contracting at different rates during cooling. Also, changes in chemical and structural properties that may occur during the thermally induced stress must be taken into account. Since bonding of dissimilar materials, particularly in high-temperature applications, is an area that can benefit significantly from the advantages provided by the disclosed method, this disclosure uses brazing to exemplify the method, but the advantages of the method are equally applicable to other bonding materials and methods such as adhesives or soldering.
- CTE coefficients of thermal expansion
- An MCA can be fabricated on the surface of any solid inorganic or organic material, including high-temperature ceramics and refractory metals, with laser treatment.
- the necessary condition is optical absorption of the laser radiation by the solid. Such absorption normally depends on the optical properties of the solid, and laser parameters such as wavelength, power, and pulse repetition rate.
- absorption of laser radiation at a particular wavelength by a solid is a preferred, but not a necessary, condition, since a solid material can be coated with a layer that absorbs the laser radiation in that particular wavelength range and this would be enough to initiate the MCA fabrication process.
- the solid material can also have a high-roughness surface, which will initially increase the absorption of the laser radiation with a positive feedback as the process is repeated. Such method allows fabrication of MCA on ceramic and even sapphire substrates by using a laser with a radiation wavelength of 1.06 ⁇ m, normally transmittable by these materials.
- MCA fabrication speed is directly proportional to average laser power. This relationship indicates that the MCA fabrication process is highly scalable and can be made more efficient by increasing laser power. Lasers of up to 5 kW are currently available, but more powerful lasers may be used as they become available. Another advantage of the MCA fabrication process is the possibility of their formation on curved and complex surfaces. This can be achieved by pre-programming the three-dimensional mechanical translation of the substrate during the laser ablation process, which may be readily accomplished using programmable stepper and servo motors.
- the formation of the MCA from capillary waves occurs due to the variation of the surface absorptivity with respect of the incidence angle of the laser radiation.
- the absorptivity of a solid decreases with increasing of the incident angles, for any radiation polarization. If the laser fluence is close to the melting threshold, the surface structures protruding towards the laser beam axis remain solid. At the same time, the areas oriented perpendicularly to the laser beam axis are evaporated at each laser pulse, and the evaporated material condenses on relatively cold protruding structures.
- the inhomogeneity of the temperature distribution along the solid surface leads to the redistribution of the melt due to temperature dependence of the surface tension coefficient. The relative contribution of these two factors (evaporation-condensation and melt displacement) to the process of the MCA formation depends both on the material and the environment.
- the spatial period between micro-columns is determined by the capillary waves on the solid and is typically 10-20 ⁇ m for most studied metals. This period is determined by the period of the capillary waves, which in turn depends on the depth of the molten layer. Thus, the spatial period of micro-columns should depend on the laser pulse duration.
- the formation of MCA occurs in a narrow window of processing parameters.
- the laser fluence should be close to the threshold of melting, or slightly above but not higher than a fluence that can cause formation of holes due to intensive evaporation of the material and re-deposition in the surrounding area.
- Such fluence depends on several material properties, including melting and evaporation points, vapor pressure at various temperatures, and reactivity with a particular ambient, and can be experimentally determined for each material by using typical MCA process setup steps that will be described below.
- the number of laser pulses at any given location should be high (of the order of 10 3 ) in order to develop the required instability.
- the laser fluence as one parameter that controls the MC formation, should be close to or slightly above the melting threshold of the solid.
- the second important parameter is the number of laser pulses. It should exceed a certain threshold value, from 10 2 to 10 4 , depending on material's absorption level at the laser maximum wavelength (see Condition 2 below).
- the laser source should have a high repetition rate in order to deliver a sufficiently high pulse number to the solid surface in a reasonably short exposure time.
- the solid material has to be highly absorbing at the chosen laser wavelength.
- the laser fluence absorbed by the solid surface should not exceed several J/cm 2 .
- Breakdown of the surrounding medium should be avoided in order to limit both shock waves and plasma development in the medium and their detrimental effect on the MCA.
- the threshold for air or (other gas) breakdown decreases in the UV and mid-IR region to around 10 ⁇ m, so laser sources operating in these ranges of wavelengths are not suitable for generation of MCA in gaseous ambient, but can be used for MCA fabrication in vacuum conditions.
- the pulse duration has to be short to avoid heat propagation to the solid substrate and its deep melting, which may destroy the MCA.
- the laser beam should be scanned over the solid surface. This is preferably achieved by placing the sample on a computer-driven X-Y stage.
- the MCA structure shown in FIG. 2 was generated by scanning the laser beam with a 50% overlap between the consecutive scans.
- the MCA should be fabricated on the surface of each bonding component, however employment of MCA on only one of the two surfaces being bonded will be also beneficial.
- post-treatments such as annealing or etching, can be applied to the MCA in order to form or selectively remove a surface layer (e.g., an oxide).
- a surface layer e.g., an oxide
- Selection of the laser treatment parameters for MCA formation is based on adjustment of the laser energy density, the pulse duration, the repetition rate, and the translation speed of the radiation absorbing sample surface, necessary for translation of the melted substance under the temperature gradient.
- a set of such parameters suitable for MCA formation always exists at appropriately selected conditions as a result of inhomogeneous absorption by a not ideally flat surface.
- the local surface temperature should be below the substance meting point when the next laser pulse reaches it (Condition 1).
- the local surface temperature is slightly below the melting temperature of the solid.
- Condition 2 applies to formation of MCA during a single scan of the laser beam. In general, there is overlapping of the laser beam during scanning back and forth for extended areas of the substrate, and Condition 2 is fulfilled due to this overlapping.
- the magnitude of each of the above parameters can change within certain limits.
- the repetition rate can change from 1 Hz to the maximum rate (f max ) at which Condition 1 will still be met.
- the unmelted material below the surface acts as a half-space thermal sink for cooling the heated surface material.
- the sample cannot be considered as a half-space thermal sink (e.g., with thin foils), it might be necessary to provide a heat sink equivalent to half-space.
- the pulse duration should not exceed the time needed (depending on sample thermal conductivity) for heat to propagate at distances comparable to the characteristic period of the MCA (Condition 4), otherwise the necessary temperature gradient necessary for the melted substance transport will not be realized.
- ambient for realizing Conditions 1, 3, and 4 during MCA formation is a vacuum.
- MCA formation without significant changes in the chemical composition is possible in open air or under a relatively non-reactive fluid—i.e., a fluid which does not result in chemical reactions causing either intensive substance removal, or formation of films on the surface, as a result of heating.
- a reactive ambient can be also applied during the MCA formation in order to achieve a desired chemical composition on the MCA surface.
- “ambient” or “ambient media” refer to whatever fluids (a fluid is understood to include all gases and liquids) are in contact with the surface during MCA fabrication, including a vacuum.
- a suitable translation stage is NEAT XY-6060 Stage and TM-400-SM single axis table (Z stage), with 4.00 inch travel each and a lead screw that is accurate to within 20 ⁇ m.
- a suitable controller is DMC-1830 XYZ controller from Galil, interfaced to a personal computer by NI-LabView virtual instrument software. This software is used in the following example of an MCA formation process. It will be apparent to a person of ordinary skill that other controllers and/or software may be substituted in the described embodiment.
- a caustic curve is a curve to which the ray of light, reflected or refracted by another curve, are tangents, the reflecting or refracting curve and the luminous point being in one plane
- the spot diameter changes behind the Z shifting is slower than that in front of it. Therefore, it is preferable to use positioning behind the shifting, which is 3 mm long.
- the laser spot translation step along one of the coordinates can be varied. It would be optimal if this translation step equals to the MCA period (specific for particular materials), which can be determined from Step 3.
- the frequency should be selected at the maximum satisfying Condition 1.
- the translation speed can have any value higher than that defined by condition 5 unless the higher speed results in not entire irradiation of the solid surface.
- defocusing is not effective in optimization of J, it can be done by placing the sample into the caustic shifting and varying the energy using filters placed outside the laser cavity, such as a set of neutral density glass filters.
- One way to reduce the MCA processing time at a limited average pulsed laser power is preheating of the substrate to just below the melting temperature. While convective or direct heating of large items is complicated and expensive, employment of a relatively inexpensive, medium power continuous wave IR laser with a wavelength suitable for heating the specific substrate material and with an unfocused beam directed on the same spot as the pulsed laser can be used, as illustrated in FIG. 3 .
- continuous wave laser 30 emits unfocused laser beam 32 striking substrate 40 heating the surface at the laser spot to nearly the material's melting point.
- pulsed laser 20 emits laser beam 22 , which preferably passes through optics 24 before striking substrate 40 further heating the substrate and causing MCA formation. For example, preheating the sample to 300° C.
- a 15 W Ar/Kr model 2020-05/2560 “white” laser from Spectra-Physics with radiation in a spectral range from 300 to 800 nm is one example of a laser that may be used for this purpose.
- the laser may be calibrated to achieve more precise laser beam focusing. It is based on digital memorizing of a “zero-point” 70 on the Z-axis coordinate set by using photosensitive materials that reproduce the laser spot image. Such calibration will be performed by slow translation of the photosensitive material surface attached to the stage simultaneously in the Z direction around the focus distance and one of the X or Y directions, while performing low-power overlapping laser shots. This will result in a pattern shown in FIG. 4 .
- the “zero-point” coordinates are those corresponding to patterned areas with minimal diameter laser spots, indicated by circle 72 in the figure.
- the pulsed laser beam is perpendicular to the material surface during MCA formation.
- this is not a critical parameter as it is believed that the angle may vary by as much as 10 or 20° without significant detrimental effect on MCA formation.
- the chemical composition of the MCA surface is critical to obtaining reliable bonds produced during the brazing process.
- the main concern is formation of unstable intermetallic compounds that might significantly reduce the bond strength.
- formation of some Ti Silicide modifications at the bond interface can result in the bond fracturing at very low loads—i.e., below ⁇ 1000 psi (Ti Silicide can form during brazing at temperatures around 800° C. or above when Ti in the brazing allow reacts with Si from the ceramic).
- Processing in reactive ambients can help form a surface that will prevent or reduce formation of intermetallics during the bonding (brazing) process.
- EDS Energy Dispersive Spectroscopy
- Si, Al, and Ba are still the main constituents of the MCA surfaces
- This method did not allow identification of either oxides or nitrides. Therefore, X-Ray Photoemission Spectroscopy measurements (XPS) were performed in order to further investigate the chemical composition of the structured surfaces. Analysis of the XPS data performed using known binding energy peak shifts associated for each compounds indicate that mostly oxides and nitrides are formed during the MCA fabrication and no sign of intermetallic compounds was present.
- XPS X-Ray Photoemission Spectroscopy
- ambient or “ambient media” refer to fluid(s) in contact with the surface during MCA fabrication or a vacuum. This allows not only for control of chemical composition of MCA, but also for real time in-situ coating of the MCA structure with a desired material. For example, the formation of oxides can be promoted by using an oxygen containing ambient, such as air, or prevented by using a neutral gas ambient.
- oxygen containing ambient such as air
- neutral gas ambient The benefits of oxidizing a metallic surface can, depending in part on the application, include improved material strength, better CTE match between the surfaces being bonded, prevention of unwanted compounds, and improved wettability.
- Ti-coated iron MCA resulted from laser ablation of an iron sample performed in a mixture of methanol and TiCl3.
- Ambient media that can be used to prevent the formation of intermetallics include Krypton, Radon, Xenon, Argon, and steam. The choice of ambient media depends on the nature of the material being treated and what, if any, changes to the surface are desired for a particular application. Therefore, numerous choices for ambient media will be apparent to a person of ordinary skill practicing the disclosed method depending on the bonding application.
- FIG. 5 is an enlarged micrograph taken from the surface of one of the micro cones formed on a Ti substrate, showing spherical TiO 2 particles.
- the ability to form oxide particles on the surface of the MCA makes it possible to improve bond strength beyond the improvement due to MCA alone.
- the nanoscale volumes between the spherical features seen in the figure can entrap bonding material and contribute to the mechanical component of bond strength.
- oxidation of the metal increases wettability of the bonding material, which also increases the mechanical component of bond strength, as discussed below.
- the presence of micro-columns, their nanoscale local features, and the modified surface chemistry results in stronger bonds.
- the surface composition of the bonding components can be pre-tailored during MCA fabrication process by providing chemical precursors from the ambient media in order to achieve desirable properties such as, for example, improved wettability, better matching of the CTE, or prevent formation of undesirable compounds that would reduce the bonding strength (e.g., some inter-metallic layers).
- desirable properties such as, for example, improved wettability, better matching of the CTE, or prevent formation of undesirable compounds that would reduce the bonding strength (e.g., some inter-metallic layers).
- laser ablation of Fe substrate performed in a mixture of methanol and TiCl 3 resulted in TiO 2 -coated Fe MCA, illustrated in FIG. 6 .
- Enlargement of the specific area in the metal-ceramic interface is one of the main MCA features to improve the bonding.
- Simple geometric calculations show a more than 10-fold increase of the specific surface for an array of micro cones with an aspect ratio (base diameter/height) of about 1.
- the wettability of a solid by a liquid is characterized in terms of the angle of contact that the liquid makes on the solid.
- s represents the force needed to stretch an interface by a unit distance (or, equivalently, the energy required to create a unit surface area of a given interface, provided that, in the case of ⁇ sv mechanical distortion and strains are negligible).
- Young's equation applies to ideal surfaces that are perfectly smooth and devoid of all chemical and structural inhomogeneities.
- the system can reside in any of the potential wells accessible to it that are commensurate with the vibrational (or thermal) energy of the droplet.
- the advancing angle is less sensitive to roughness than is the retreating angle and is usually the one measured and reported.
- MCA are more flexible than a flat epoxy-metal interface, and will more readily deform under stress induced by either difference in CTE or under shear deformation. This is schematically shown in FIG. 1 .
- Objects 61 and 62 with differing CTE, are bonded with bonding material 64 .
- FIG. 7 illustrates micro-deformation of cones under shear stress in the presence of an adhesive or braze. Initially micro-cones 56 are in their original unstressed positions.
- micro-cones 56 bend or flex into new positions 58 .
- This ability to bend absorbs some of the stress reducing the stress on the micro-cone bonding material interface and the stress in bonding material 54 .
- bending of multiple micro-cones compensates the variation of the contact length between the ceramics and metal, so that the total stress is reduced through this bending.
- the disclosed method is particularly well-suited for furnaceless brazing methods.
- the heat for furnaceless brazing is created by placing reactive materials on or near the braze between the two surfaces being bonded and reacting them to release heat. The heat released must be sufficient to melt the braze.
- An intermediate step of applying a prebraze to the bonding surfaces, which may require furnace heating, prior to placing the reactive materials and braze in place may be necessary.
- One example of a furnaceless brazing method is the NanoBond® method developed by Reactive NanoTechnologies, Inc. The method is described by A. Duckham, M. Brown, E. Besnoin, D. van Heerden, O. M. Knio, & T. P. Wells, Metallic Bonding of Ceramic Armor Using Reactive Multilayer Foils , American Ceramic Society Meeting, Coco Beach, Fla., Jan. 25-29, 2005, pp. 597-603, which is incorporated in its entirety herein by reference.
- the heat is provided by a reactive NanoFoil®, which comprises thousands of alternating nanoscale layers of Ni and Al. An exothermic reaction between the layers is triggered by an external energy impulse.
- NanoBond® method for applications that involve bonding of very dissimilar materials are: 1) large and complexly shaped parts can be bonded without using a furnace; 2) thermal stress due to differences in the CTE that builds up during high temperature bonding can be greatly reduced by localization of the heat at the interface within the brazing layers; and 3) it is environmentally safe and cost-effective.
- NanoBond® process is as follows. Brazing alloy is pre-applied to the components being bonded. NanoFoil® is then placed between the components. The components are properly aligned and pressed together to encourage the molten solder and braze to flow and wet the components after the NanoFoil® is activated to chemically react and produce heat to melt the solder or braze.
- Such joints offer approximately ten times the thermal conductivity of thermal epoxies along with the ability to bond in air, without the use of fluxes, and to have a bond that allows rework of damaged parts.
- Some of the specific applications that can benefit from this are defense, space, avionics, laser systems, and high performance computers.
- an MCA structure was produced via laser ablation of a solid surface by a pulsed excimer laser with an energy output of a few joules, a pulse duration from 0.002 to 1.5 ⁇ s, and a wavelength from 0.2 to 11.00 ⁇ m.
- Such laser characteristics allow variation of the MCA fabrication process parameters and materials used for MCA fabrication across a wide range.
- Mechanical property measurements on adhesive bonds formed between Ti/Ti show that the strength increased due to (i) considerable increase in surface area, and (ii) improvement of the solid/adhesive interface due to modifications in the surface chemistry. When the process is carried out in air the micro column surfaces oxidize.
- FIG. 8 is an SEM micrograph showing the surface of a fractured epoxy layer used to bond two MCA-structured Ti plates. This micrograph confirms that debonding did not occur at the adhesive/adherent boundary.
- Application of MCA process results in more than a 4-fold increase in the fracture strength as compared to the bonding of an unmodified surface, as shown in FIG. 9 .
- the first set included samples with unstructured Ti alloy and IRBAS ceramic surfaces, as well as samples with a MCA-structured IRBAS ceramic surface and unstructured Ti alloy surface.
- the second set included samples with both Ti alloy and IRBAS ceramic MCA-structured surfaces.
- the results achieved from laboratory shear stress testing of this set of samples, shown in FIG. 11 indicate an average of about 53% increase in the bond strength when using the MCA structuring of the ceramic surface only.
- lines 1 and 3 represent samples with MCA formed on the ceramic surface.
- Line 2 represents an untreated sample.
- FIG. 12 shows the results of testing additional samples. For two samples, MCA were formed on the IRBAS ceramic surface only. For two samples, MCA were formed on both surfaces. The final two samples lacked MCA on either surface. The tests showed an increase of up to 90% with two treated surfaces compared to one treated surface.
- Lines 1 and 2 represent the plain (no MCA) samples.
- Lines 3 and 4 represent the samples with MCA on the ceramic surface only.
- Lines 5 and 6 represent samples with MCA on both surfaces.
- the MCA were fabricated on the IRBAS surface using a pulsed 60 W Nd:YAG laser with a wavelength of 1064 nm and a computer-driven X-Y stage allowing displacement with an accuracy of 1 ⁇ m under radiation with the laser beam.
- testing indicated strength values of up to 11,000 psi for shear tests on conventionally brazed MCA-structured samples and up to 1,926 psi for tensile tests of MCA-structured samples bonded with the NanoBond® process.
- the highest strength obtained in experiments by Molitor P, Yong T, Int. J. Adhes. Adhes. 2002; 22: 101, on Ti alloy samples bonded by an epoxy “AF-3109-2K”, which is widely used in aerospace industry, dispersed with glass fibers, and using extensive surface preparation is 15.9 MPa.
- the result shows that the limiting factor in the total bond strength is the adhesive strength.
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Abstract
Description
W ad=σ1v+σ2v−σ12=(E 1 tot +E 2 tot +E 12 tot)/As
TABLE 1 |
Exemplary laser sources suitable for MCA generation |
Repetition | |||
Laser type | Wavelength (nm) | Pulse duration (ns) | rate (kHz) |
Cu vapor | 514 | 10-20 | 10-20 |
Au vapor | 635 | 10-20 | 10-20 |
Nd:YAG | 1064 | 20-120 | 5-60 |
Nd:YAG (2nd | 532 | 25-80 | 5-60 |
harmonics) | |||
(D/V)*f=n (Condition 2)
where D is the laser beam width, V is the translation speed, f is the repetition rate, and n is the number of laser pulses, which typically is between about 102 and about 104 depending on the substrate's adsorption at the laser wavelength being used.
-
STEP 1
-
STEP 2
-
STEP 3
- STEP 4
S=S 0(1−f)+fS 0k
σLV cos θ+σLS=σSV
where σLV, σLS, and σSV are the interfacial tensions at the boundaries between liquid (l), solid (s), and vapor (v). Here, s represents the force needed to stretch an interface by a unit distance (or, equivalently, the energy required to create a unit surface area of a given interface, provided that, in the case of σsv mechanical distortion and strains are negligible). The condition θ<90° indicates that the solid is wet by the liquid, and θ>90° indicates nonwetting, with the limits θ=0° and θ=180° defining complete wetting and complete nonwetting, respectively. A large body of useful scientific information about the wettability of and spreading upon high-temperature metal and ceramic coatings comes from the application of Young's equation to metallurgical systems at elevated temperatures.
cos θw=r cos θy
where r is the ratio of the true wetted area to the apparent area.
Claims (8)
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